Expandable implant, instrument, and method

ABSTRACT

Embodiments of the invention include expandable, implantable devices and methods. Devices expand linearly to provide secure fixation between or among anatomical structures. In some embodiments, an implant replaces one or more vertebral bodies of the spine.

FIELD OF THE INVENTION

The present invention relates generally to the field of replacingportions of the human structural anatomy with medical implants, and moreparticularly relates to an expandable implant and method for replacingskeletal structures such as one or more vertebrae or long bones.

BACKGROUND

It is sometimes necessary to remove one or more vertebrae, or a portionof the vertebrae, from the human spine in response to variouspathologies. For example, one or more of the vertebrae may becomedamaged as a result of tumor growth, or may become damaged by atraumatic or other event. Removal, or excision, of a vertebra may bereferred to as a vertebrectomy. Excision of a generally anteriorportion, or vertebral body, of the vertebra may be referred to as acorpectomy. An implant is usually placed between the remaining vertebraeto provide structural support for the spine as a part of a corpectomy.FIG. 1 illustrates four vertebrae, V₁-V₄ of a typical lumbar spine andthree spinal discs, D₁-D₃. As illustrated, V₃ is a damaged vertebra andall or a part of V₃ could be removed to help stabilize the spine. Ifremoved along with spinal discs D₂ and D₃, an implant may be placedbetween vertebrae V₂ and V₄. Most commonly, the implant inserted betweenthe vertebrae is designed to facilitate fusion between remainingvertebrae. Sometimes the implant is designed to replace the function ofthe excised vertebra and discs. All or part of more than one vertebraemay be damaged and require removal and replacement in somecircumstances.

Many implants are known in the art for use in a corpectomy procedure.One class of implants is sized to directly replace the vertebra orvertebrae that are being replaced. Another class of implants is insertedinto the body in a collapsed state and then expanded once properlypositioned. Expandable implants may be advantageous because they allowfor a smaller incision when properly positioning an implant.Additionally, expandable implants may assist with restoring properloading to the anatomy and achieving more secure fixation of theimplant. Implants that included insertion and expansion mechanisms thatare narrowly configured may also provide clinical advantages. In somecircumstances, it is desirable to have vertebral endplate contactingsurfaces that effectively spread loading across the vertebral endplates.Effective implants should also include a mechanism for securely lockingin desired positions, and in some situations, being capable ofcollapsing. Fusion implants with an uninterrupted opening between theirends may also be advantageous because they allow for vascularization andbone growth through the entire implant.

Expandable implants may also be useful in replacing long bones orportions of appendages such as the legs and arms, or a rib or other bonethat is generally longer than it is wide. Examples include, but are notlimited to, a femur, tibia, fibula, humerus, radius, ulna, phalanges,clavicle, and any of the ribs.

SUMMARY

One embodiment of the invention is an expandable medical implant forsupporting skeletal structures. The implant includes a first tubularmember with a connection end and an opposite skeletal interface end, anda second tubular member with a connection end configured to engage withthe connection end of the first tubular member, the second tubularmember having an opposite skeletal interface end. A key pin is fixed tothe first tubular member and positioned in a slot in the second tubularmember so that the key pin guides translation between the first tubularmember and the second tubular member.

An embodiment of the invention is an expandable medical implant forsupporting skeletal structures having a first tubular member with aconnection end and an opposite skeletal interface end, and a secondtubular member with a connection end configured to engage with theconnection end of the first tubular member, the second tubular memberhaving an opposite skeletal interface end. The second tubular memberintermittently locks relative to the first tubular member as the implantis expanded. In use in some embodiments, the implant includes aninsertion instrument for translating the first tubular member relativeto the second tubular member. The insertion instrument has a first tipfor attaching to the skeletal interface end of the first tubular member,a second tip for attaching to the skeletal interface end of the secondtubular member, and a spreader mechanism for translating the first tipaway from the second tip. Moving the first tip toward the second tipresults in the first tubular member being released relative to thesecond tubular member to permit the expandable medical implant to bereduced in length.

Another embodiment of the invention is an end member for a medicalimplant having a length. The end member is configured to interface witha skeletal structure at the end of the medical implant's length. In someembodiments, the end member includes an end cap with a thickness thatprovides connection to the medical implant and connection to theskeletal structure, and a shoe for attachment to the end cap. The shoespans at least a portion of an opening through the end cap, and providesat least in part an interface with the skeletal structure.

An additional embodiment of the invention is a method of placing amedical implant between skeletal structures with an insertioninstrument. The method includes accessing a surgical site and expandingthe medical implant to fit in a space between skeletal structures bymoving at least a portion of the insertion instrument in a firstdirection. The medical implant progressively locks as expanded. If thelocked implant needs to be released from the locked position, the lockedimplant is released by moving the portion of the insertion instrument ina generally opposite direction.

Yet another embodiment of the invention is an expandable device forsupporting skeletal structures. The embodiment includes an implant meansfor expanding into a space between skeletal structures in aprogressively locked state, and an instrument means for expanding theimplant into the space by movement of at least a portion of theinstrument in a first direction. Movement of the at least a portion ofthe instrument in a generally opposite direction releases the lockedstate of the implant.

Another embodiment of the invention is an expandable medical implant forsupporting skeletal structures, the medical implant having a lengthalong its expandable dimension. The implant embodiment includes a firsttubular member with a connection end, an opposite skeletal interfaceend, and a central expansion instrument opening. The implant embodimentalso includes a second tubular member with a connection end configuredto engage with the connection end of the first tubular member. Thesecond tubular member has an opposite skeletal interface end.Embodiments of the invention include an expansion instrument insertablethrough the central expansion instrument opening and expandable againstthe first tubular member and the second tubular member to expand themedical implant. The combined first and second tubular members are of agreater dimension along the length of the implant than the combinedfirst and second tubular members are in any dimension perpendicular totheir length.

An embodiment of the invention is a method of placing an expandablevertebral body replacement device that includes making an incisionadjacent to a vertebral body, removing at least a portion of thevertebral body, and placing an expandable vertebral body replacementdevice on an insertion end of a contracted expansion instrument. Thecontracted expansion instrument is configured to pass through a centralportion of the expandable vertebral body replacement device withoutextending onto any surface of the expandable vertebral body replacementdevice that is lateral to an insertion direction. The method embodimentalso includes inserting the vertebral body replacement device at leastin part into a volume left open after removal of the portion of thevertebral body, expanding the expansion instrument to secure thevertebral body replacement device, and removing the expansion instrumentthrough the incision.

Another embodiment of the invention is a device for supporting skeletalstructures having an expandable implant with a first tubular member anda second tubular member and having a means for receiving an expansioninstrument, and an expansion instrument means for expanding against thefirst tubular member and the second tubular member to expand the medicalimplant. The expansion instrument means is centrally located on theexpandable implant such that when the expandable implant is placed in aperson to support the skeletal structures with the expansion instrumentmeans attached, ends and lateral extents of the expandable implant areviewable from the direction of insertion of the implant.

An embodiment of the invention is an expandable medical implant with alength along its expandable dimension. The medical implant is forsupporting skeletal structures. The implant includes a first tubularmember with a connection end having a first set of protrusions and anopposite skeletal interface end. The implant embodiment includes asecond tubular member with a connection end including a second set ofprotrusions configured to engage with the connection end of the firsttubular member, the second tubular member including an opposite endopposite from the connection end. The first set of protrusions includesa flank with a negative flank angle. The flank is positively loaded whenthe implant is compressively loaded along its length.

Another embodiment of the invention is an expandable medical implantwith a length along its expandable dimension. The medical implant is forsupporting skeletal structures and includes a first tubular member witha connection end having a first set of protrusions and an oppositeskeletal interface end. The implant also includes a second tubularmember with a connection end having a second set of protrusionsconfigured to engage with the connection end of the first tubularmember. The second tubular member has an opposite end opposite from theconnection end. Compressively loading the implant along its lengthgenerates a compressive force between the first and second tubularmember transverse to the length of the implant. This force tends to moresecurely engage the first and second sets of protrusions.

Yet another embodiment of the invention is an expandable medical implantwith a length along its expandable dimension, the medical implant forsupporting skeletal structures. The embodiment of the implant includes afirst tubular member with a connection means, a second tubular memberwith a connections means for coupling with the first tubular member,means for translating the first tubular member relative to the secondtubular member to provide coarse expansion adjustment, and means forproviding fine length adjustment by turning the second tubular memberrelative to the first tubular member.

Still another embodiment of the invention is a method of implanting anexpandable medical implant with a length along the expandable dimensionof the implant. The method embodiment includes the acts of pulling afirst tubular member with a first set of threads away from a secondtubular member with a second set of threads, causing the first andsecond sets of threads to translate relative to one another along thelength of the implant, and turning the second tubular member relative tothe first tubular member to adjust the expanded length of the medicalimplant.

An embodiment of the invention is a method of implanting an expandablemedical implant with a length along the expandable dimension of theimplant. The embodiment includes the act of pulling a first tubularmember with a first set of right-hand threads away from a third tubularmember with a fourth set of left-hand threads. The medical implantcomprising a second tubular member with a second set of right-handthreads and a third set of left-hand threads, the act of pulling causingthe first and second sets of threads to translate relative to oneanother along the length of the implant and the third and fourth sets ofthreads to translate relative to one another along the length of theimplant. An additional act of the embodiment is turning the secondtubular member relative to the first and third tubular members to adjustthe expanded length of the medical implant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view of a segment of a lumbar spine.

FIG. 2 is a perspective view of an expandable implant.

FIG. 3 is side cross-sectional view of the implant of FIG. 2.

FIG. 4 is an enlarged view of a portion of the implant illustrated inFIG. 3.

FIG. 5 is an exploded view of the implant of FIG. 2.

FIG. 6 is a perspective view of the implant of FIG. 2 and an attachedinstrument.

FIG. 7 is an enlarged perspective view of the implant of FIG. 2 and aportion of an attached instrument.

FIG. 8 is an elevation view of the implant of FIG. 2 and a portion of anattached instrument in an expanded state.

FIG. 9 is an elevation view of the implant of FIG. 2 and a portion of anattached instrument in an expanded state, and with the instrumentpositioned to release the implant for collapsing.

FIG. 10 is a side cross-sectional view of the implant and instrument ofFIG. 9.

FIG. 11 is a partially exploded perspective view of an embodiment of theimplant.

FIG. 12 is a perspective view of an embodiment of an end shoe.

FIG. 13 is a perspective view of the implant of FIG. 11.

FIGS. 14A and 14B are perspective views of implants embodiments ofvarying sizes.

FIG. 15 is a perspective view of an implant embodiment attached to amodular embodiment of an instrument.

FIG. 16 is a partially exploded perspective view of a connection withinthe modular instrument of FIG. 15.

FIG. 17 is a perspective view of another expandable implant embodimentand a portion of an attached instrument.

FIG. 18 is a perspective view of the implant and instrument of FIG. 17in a more expanded state.

FIG. 19 is a partially cut away perspective view of a component of theimplant of FIG. 17.

FIG. 20 is an elevation view of a component of the implant of FIG. 17.

FIG. 21 is a perspective view of another expandable implant embodimentand a portion of an attached instrument between vertebrae.

FIG. 22 is a perspective view of the implant and instrument of FIG. 21in a more expanded state.

FIG. 23 is perspective view of the superior end of the implant of FIG.21 with a partially cut away section.

FIG. 24 is an enlarged perspective view of the superior end of theimplant of FIG. 21.

FIG. 25A is a cross-sectional view of a prior art thread profile.

FIG. 25B is a cross-sectional view of protrusions of an embodiment ofthe implant of FIG. 21.

FIG. 26 is perspective view the inferior end of the implant of FIG. 21with a partially cut away section.

DETAILED DESCRIPTION

FIGS. 2-5 illustrate an expandable medical implant 1 for supportingskeletal structures. In the illustrated embodiment, the medical implant1 includes a first tubular member 10 with a connection end 11 andopposite first skeletal interface end 12, and a second tubular member 20with a connection end 21 configured to engage with the connection end 11of the first tubular member 10. The second tubular member 20 has anopposite second skeletal interface end 22. A key pin 13 is fixed to thefirst tubular member 10 and positioned in a slot 23 in the secondtubular member 20 such that the key pin 13 guides translation betweenthe first tubular member 10 and the second tubular member 20. Theembodiment shown includes a medial aperture 5 through which bone growthmaterial may be packed and through which bone growth may occur.Additionally, the medial aperture 5 is an aid in radiographic assessmentwhen the implant 1 is made from a material that is not radiolucent.Openings 6 are also useful for packing of bone growth material, andprovide channels through which bone growth may occur.

The term tubular as used herein includes generally cylindrical membersas are illustrated in FIG. 2, but may also include other enclosed orpartially enclosed cross-sectional shapes. By way of example and withoutlimitation, tubular includes fully or partially, cylindrical,elliptical, rectangular, square, triangular, semi-circular, polygonal,and other cross-sectional shapes of these general types.

The illustrated key pin 13 guides the translation of the first andsecond tubular members 10, 20 and provides torsional stability betweenthe tubular members 10, 20. In addition, as shown in FIG. 2, the key pin13 provides a positive stop to the expansion of the medical implant 1 bylimiting the travel of the second tubular member 20 with interferencebetween the key pin 13 and the bottom 24 of the slot 23. Similarly, thekey pin 13 provides a positive stop to the contraction of the medicalimplant 1 by limiting the travel of the second tubular member 20 with aninterference between the key pin 13 and the top 26 of the slot 23. Aswill be described in more detail below, the key pin 13 also provides aconnection interface between an insertion instrument and the firsttubular member 10.

As shown in the illustrated embodiment, the first tubular member 10 fitswithin the second tubular member 20. However, in other embodiments, thefirst tubular member may be of greater diameter than the second tubularmember with the connection between the two members being reversed inorientation. Alternatively, the first and second tubular members may beof approximately the same size, but have legs that exist coplanarly orwithin the same tubular geometry with the legs of the other.

As shown in FIGS. 2, 3, and 5, the first tubular member 10 includes arelief cut 14 to facilitate portions of the first tubular member 10flexing away from the second tubular member 20 to permit translationbetween the first and second tubular members. The flexing may be inducedby pulling the first tubular member 10 away from the second tubularmember 20 to expand the medical implant 1. Referring now to FIG. 4,pulling the first tubular member 10 down while pulling the secondtubular member 20 up causes the inclined first flank 17 of the firstprotrusions, or first set of teeth 15, to press against the second flank27 of the second protrusions, or second set of teeth 25. Because thesecond tubular member 20 has a continuous cross-section, it has arelatively stronger lateral resistance than the first tubular member 10with its relief cut 14. Therefore, the force induced between the firstand second flanks, 17, 27, causes the first tubular member 10 to flexaway from the second tubular member 20. In other embodiments, a reliefcut in the second tubular member 20 and a continuous shape in the firsttubular member 10 could cause flexing of the second tubular memberrather than the first. The degree and direction of flexing can becontrolled by the use of different materials, various degrees of reliefcutting, different cross-sectional shapes, and the shapes of the teethor protrusions employed, among other factors. The force required forvarious degrees of flexing of the members is proportional to the forcerequired to expand the implant. Therefore, the force required to expandthe implant may be maintained within a desirable range by controllingthe factors detailed above.

As best illustrated in FIGS. 3 and 4, the first tubular member 10includes a set of first teeth 15, or more generally, protrusions,wherein the rows of teeth are adjacent to one another. The secondtubular member 20 includes a set of second teeth 25, or more generally,protrusions, wherein the rows of teeth are not adjacent to one another.As shown, every other row of the set of second teeth 25 has beenremoved. However, in other embodiments, every third or fourth or someother number of rows may contain teeth, or the tooth pattern may repeatin some non-uniform fashion. If the sets of teeth were threads instead,a similar effect could be achieved by widening the pitch of the threadson one of the tubular members.

The first set of teeth 15 interdigitate with every other one of theteeth of the set of second teeth 25. This or other varied spacings maybe advantageous. As noted above, the force required to expand theimplant is proportional to the number of sets of teeth that are incontact while the tubular members 10, 20 are being translated. However,if teeth on both tubular members 10, 20 are spaced apart at greaterdistances, the number of increments to which the implant may be adjustedis decreased. By maintaining the frequency of the rows of the first setof teeth 15 and increasing frequency of the second set of teeth 25, theforce required to expand the implant is reduced, but the number ofdiscrete points of adjustment is not reduced. In some embodiments, theincreased frequency of teeth could be maintained on the second tubularmember 20 while the spacing is increased on the first tubular member 10.

FIG. 6 illustrates an insertion instrument 50 for expanding the implant1. The insertion instrument 50 includes an outer shaft 51 and in innershaft 53 disposed within the inner shaft 51. A counter-torque handle 55is coupled to the outer shaft 51. A drive handle 57 is coupled to theproximal end of the inner shaft 53. A rack and pinion assembly 60 iscoupled to the distal end of the outer shaft 51 and the inner shaft 53.

Referring now to FIG. 7, the rack and pinion assembly 60 includes alower rack 61 and an upper rack 62 along with a pinion (not shown),which is disposed on the end of the inner shaft 53. The lower rack 61has a first socket 71 for receiving a first tip 81. The first tip 81connects to the first tubular member 10 near the first skeletalinterface end 12. As illustrated, two retainers 19 prevent the first tip81 from moving along the implant away from the first skeletal interfaceend 12. The upper rack 62 has a second socket 72 for receiving a secondtip 82. The second tip 82 connects to the second tubular member 20 nearthe second skeletal interface end 22. The second tubular member 20 ofthe illustrated embodiment does not have any mechanism for restrictingthe movement of the second tip 82 away for the second skeletal interfaceend 22.

When the drive handle 57 is rotated in a clockwise direction, the innershaft 53 actuates the rack and pinion assembly, spreading the first andsecond tips 81, 82, and expanding the implant 1. Other embodiments ofthe insertion instrument 50 may operate by motions other than turning ofa handle or knob, or may expand as a result of counter-clockwiserotation. For example and without limitation, the spreading motion maybe created by a linkage system such as pliers, by a ratcheting orscrew-driven jack, by pull or push grip handles, or by pneumatic orelectric actuators. The alternative mechanisms may be reversible or twoseparate instruments may be used to expand and compress the tips of theinstrument. Instruments such as those disclosed in U.S. patentapplication Ser. No. 10/441,689, entitled “Instruments and Techniquesfor Separating Bony Structures,” filed May 20, 2003; and U.S. patentapplication Ser. No. 11/291,419, entitled “End Device for a VertebralImplant,” filed Dec. 1, 2005 may be used in embodiments of the inventionand these applications are hereby incorporated by reference in theirentirety. In some embodiments, the rack and pinion assembly 60 is offsetlaterally from the outer shaft to provide direct visualization of theimplant in the surgical site. Instruments of any of these varieties maybe used as part of or in combination with implants 1, 1 a, 100, and 200,specifically disclosed herein or as otherwise effectively applied.

The implant 1 of the illustrated embodiment progressively locks asexpanded. The expansion may also be described as intermittent sincelocking occurs at the discrete locations where teeth from the first andsecond sets of protrusions align.

FIGS. 8-10 illustrate the implant 1 being expanded and then released bythe first and second tips 81, 82 of the insertion instrument 50. FIG. 8shows the implant in a fully expanded condition with the key pins 13contacting the bottom 24 of the slot 23. In FIGS. 9 and 10, the firstand second tips 81, 82 have been contracted to apply a force to the keypins 13. In the illustrations, the second tip 82 is in position to applya flexing force to the key pins 13, but has not yet applied sufficientforce for the key pins 13 to be moved inwardly. The first and secondtips 81, 82 are drawn together by turning the drive handle 57 in acounter-clockwise direction in this embodiment. Two retainers 19 preventthe first tip 81 from moving along the implant 1 away from the firstskeletal interface end 12, but the second tip 82 is able to move awayfrom the second skeletal interface end 22 to contact the key pins 13. Insome embodiments, the second tip 82 includes at least one capturemechanism 83 for engaging a portion of one or more of the key pins 13.Because the capture mechanism 83 and the key pin 13 make contact alongan inclined surface, downward motion of the second tip 82 causes the keypin 13, and thus the first tubular member 10, to flex inwardly. Inwardflexing of the first tubular member 10 disengages the first set of teeth15 from the second set of teeth 25 and releases locking between thefirst and second tubular members 10, 20.

In addition to releasing locking, the capture mechanism 83 enables asecure temporary connection to the implant 1 by the insertion instrument50. With the implant 1 held in the insertion instrument 50, the implant1 may be positioned, re-positioned, or removed from the surgical site.In other embodiments, a capture mechanism may be a feature of the firsttip 81. In such embodiments, release of the locking may be keyed toforce or motion from an action delivered through the first tip 81.

The insertion instrument 50 in combination with the first and secondtubular members 10, 20 provides a significant clinical advantage in someembodiments. The combination enables insertion, expansion, locking, andcontraction without the need for exchanging instruments or addingadditional pieces to the device. The illustrated implant 1 automaticallylocks as expanded. The insertion instrument 50 is capable of holding,expanding, contracting, and repositioning the implant 1 without everbeing removed from the surgical site.

Generally stated, the insertion instrument 50 in combination with theimplant 1 is an expandable skeletal structure support device thatprogressively locks as expanded. Movement of at least a portion of theinstrument in a first direction generates the expansion, and generallyopposite movement releases the locked state of the implant 1.

In practice, an implant such as the implant 1 is placed between skeletalstructures by first accessing the surgical site. Access may be throughany surgical approach that will allow adequate visualization and/ormanipulation of the skeletal structures. Example surgical approachesinclude, but are not limited to, any one or combination of anterior,antero-lateral, posterior, postero-lateral, transforaminal, and/or farlateral approaches. Implant insertion can occur through a single pathwayor through multiple pathways, or through multiple pathways to multiplelevels of the spinal column. Minimally invasive techniques employinginstruments and implants are also contemplated. Similar approaches andpathway are applicable to implants 100 and 200.

With access established, the medical implant 1 is placed and expanded tofit in a space between skeletal structures. It is often necessary tofurther open or prepare the space between skeletal structures, which canbe done by any technique available to the surgeon. Expansion of theimplant 1 may be carried out by moving at least a portion of theinsertion instrument 50 in a first direction, as detailed herein.Embodiments of the implant 1 progressively lock as expanded by theinsertion instrument 50. In some circumstances, it is desirable torelease the implant 1 from its locked state. For example, upon initialplacement and assessment under fluoroscopy, a determination may be madethat the implant 1 is not appropriately placed or sized. As described indetail in association with FIGS. 9 and 10, generally opposite motion ofa portion of the insertion instrument 50 releases the locked implant.

FIGS. 14A and 14B show a range of implant sizes that may be useful in aclinical setting. The implant in FIG. 14A is approximately 13 mm indiameter and may range from approximately 16 mm to 20 mm in height. Theimplant in FIG. 14B is approximately 25 mm in diameter and may rangefrom approximately 50 mm to 65 mm in height. These are not limitingsizes for the disclosed implants, but are only examples of varioussizes. As is evident from the variation in size, a conventional, singleinsertion instrument 50 would not have an appropriate grasping mechanismto secure, expand, and insert all instrument sizes. However, embodimentsof the present invention include tip mechanisms for inserting implantsof various sizes. As illustrated in FIG. 7, the lower rack 61 has afirst socket 71 for receiving a first tip 81. The first tip 81 connectsto the first tubular member 10 near the first skeletal interface end 12.The upper rack 62 has a second socket 72 for receiving a second tip 82.The second tip 82 connects to the second tubular member 20 near thesecond skeletal interface end 22. Embodiments of the invention include aset of two or more variously sized first interchangeable tips that maybe placed in the first socket 71 one at a time to accommodate firsttubular members 10 of different, matching sizes. Likewise, embodimentsalso include a set of two or more variously sized second interchangeabletips that may be placed in the second socket 72 one at a time toaccommodate second tubular members 20 of different, matching sizes.First and second interchangeable tips may be used in any combination toaccommodate respective tubular member pieces.

FIGS. 15 and 16 illustrate an embodiment of an insertion instrument thatis configured to provide modular rack and pinion assemblies that matchimplants. Rather than, or in addition to, sets of tips to match implantsizes, the modular insertion instrument 150 provides for a set of distalcomponents 150 b that fit a set of variously sized implants 1. Thevarious distal components 150 b match a standard torque base 150 a thatcouples to the distal component 150 b and applies torque to thecomponent. The standard torque base 150 a includes a proximal innertorque shaft 153 a, a proximal outer torque shaft 151a disposed aboutthe proximal inner torque shaft 153 a, and an adjustable counter torquehandle 155. The adjustable counter torque handle 155 may be loosened,positioned at any radial angle about standard torque base 150 a,tightened, and used to hold the proximal outer torque shaft 151 a steadywhile applying torque to the proximal inner torque shaft 153 a. A torquehandle of any effective type may be applied to the end of the proximalinner torque shaft 153 a to turn the shaft.

Each distal component 150 b includes a distal outer torque shaft 151 band a distal inner torque shaft 153 b. The distal inner torque shaft 153b has a distal inner torque coupling 152 b and a retaining notch 154.The distal inner torque coupling 152 b fits in a corresponding proximalinner torque coupling (not shown) to transfer torque from the proximalinner torque shaft 153 a to the distal inner torque shaft 153 b. Theretaining notch 154 is configured to receive one or more detent balls156 to restrict movement of the distal component 150 b away from theproximal component 150 a. The proximal outer torque shaft 151 a and thedistal outer torque shaft 151 b also couple through a torque fitting. Acoupling sleeve 152 is disposed over the outer torque shafts 151 a, 151b to maintain their alignment and to keep the detent balls 156 engagedin the retaining notch 154. The coupling sleeve 152 is maintained in apredetermined range by attachment to retaining pin 158. A retainingspring 159 keeps the coupling sleeve 152 biased over the joint betweenthe outer torque shafts 151 a, 151 b.

In operation, to load a distal component 150 b into the proximalcomponent 150 a, the coupling sleeve 152 is pulled proximally, and thedistal component 150 b is inserted into the proximal component 150 a.The coupling sleeve is allowed to slide over the joint between thecomponents, and the instrument is ready for use. To remove the distalcomponent 150 b, the coupling sleeve 152 is pulled proximally and thedistal component 150 b is removed from the proximal component.Similarly, various distal components with differently sized implants maybe coupled to the proximal component 150 a.

FIG. 11 shows an inferior end member 3 and a superior end member 4coupled to and in an exploded view relationship with a medical implant 1a. As illustrated, the medical implant 1 a is a corpectomy device, butcould in other embodiments be a device for positioning within a longbone or other structure. The end members 3, 4 could also be coupled todevices such as, but not limited to, the implants illustrated in FIGS.2, 17, and 21. By way of example, superior end member 4 of FIG. 11 isaligned with a medical implant 1 a that has a length. The superior endmember 4 is configured to interface with a skeletal structure at the endof its length through spikes 31, in the illustrated example, and bybearing of its various components against the skeletal structure. Thesuperior end member 4 includes an end cap 30 with a thickness thatprovides connection to the medical implant 1 a and connection to theskeletal structure, and a shoe 40. The shoe 40 attaches to the end cap30 and spans at least a portion of an end cap opening 35. The shoe 40provides at least in part an interface with the skeletal structure.

The end cap 30 may be a separate component, as illustrated, or may beintegrated with an implant such as the medical implant 1 a. The endmember 4 in total and the end cap 30 may be of a uniform thickness, asshown in FIG. 11, or one or both of the end member 4 and the end cap 30,30 a may vary in thickness, as shown in FIG. 5, such that placement ofthe end member 4 on the medical implant 1 creates an interface with theimplant 1 that is not parallel to the length of the implant 1. Thisnon-parallel configuration may enable the end member 4 and the medicalimplant 1 to match the natural angles of a spinal curvature. Forexample, in much of the cervical and lumbar regions of the spine, thenatural curvature is a lordotic angle. In much of the thoracic region ofthe spine, the natural curvature is a kyphotic angle.

As shown in FIG. 11, the superior end cap 30 includes a number ofsurface irregularities that may aid connection or interface with theskeletal structure. The surface irregularities illustrated are spikes 31that are sharp to penetrate the skeletal structure. In otherembodiments, the surface irregularities may be raked or straight teeththat tend to bite into the skeletal structures to resist expulsion inparticular directions, such as, for example, to resist expulsionopposite to the path of insertion. The surface irregularities may be asurface finish, sprayed coating, or mechanical or chemical etching. Thesurface irregularities may be fixed, or may retract and deploy into aposition to engage the skeletal structures.

The end cap 30 shown includes cap connectors 42 for coupling the end cap30 to the medical implant 1 a. The cap connectors 42 shown are roundpins, but in other embodiments could be other shapes and could includeother functions. For example, the cap connectors 42 may be square incross-section or any other geometric shape. The cap connectors 42 may beoblong for sliding in slots into which they could be engaged, or mayhave hooked ends to grasp or otherwise capture a portion of the medicalimplant 1 a when coupled. The implant 1 a of FIG. 11 includes slicedopening 43 along with other openings for receiving the cap connectors42. The sliced opening 43 includes a cut 44 that creates a flexible,living hinge capable of securely receiving one of the cap connectors 42.When a cap connector 42 is pushed into the sliced opening 43, the slicedopening 43 deforms to open and allows the cap connector 42 to slide intothe sliced opening 43. After the cap connector 42 is seated in thesliced opening 43, the material returns to its pre-insertion positionand creates a locking effect around the cap connector 42. In addition,or in the alternative, the cap connectors 42 may include relief cutsthrough some or all of their cross section to provide a living hinge orspring effect when inserted into an appropriately sized opening.

As illustrated in FIGS. 5 and 11, each of the end caps 30, 30 a haseight equally radially spaced cap connectors 42. This spacing allows forthe rotational orientation of the end caps 30, 30 a to be altered atforty-five degree increments relative to the tubular members. Theadjustable rotational orientations enable implants with end caps ofvarying thicknesses, such as end cap 30 a, to be placed fromsubstantially any surgical approach and simultaneously properly matchthe skeletal structures. For example, to match lordotic or kyphoticspinal angles while approaching from any of anterior, antero-lateral,posterior, postero-lateral, transforaminal, and far lateral approaches.Multiples other than eight may be used in various embodiments, andembodiments with spacing that is not equal may be employed to limit ordirect orientation possibilities. The cap connectors 42 illustrated arepart of the end caps 30, 30 a, but in other embodiments, cap connectorsmay extend from the implants 1, 1 a, 100, or 200, and be connectable toopenings in respective end caps.

FIGS. 5 and 11 illustrate a superior shoe 40 that is concavely shapedrelative to the end members 30, 30 a. In some embodiments, thisconfiguration may be advantageous because it provides for a small basketarea in the central portion o the superior shoe 40. The basket area maybe useful in receiving a portion of bone growth material that can beheld directly against an endplate, or may be useful in matching andsupporting certain anatomical structures. An inferior shoe 41 is shownin FIGS. 5 and 13 that is convexly shaped relative to the end members30, 30 a. This shape may be useful for a number of purposes, includingmatching and supporting adjacent anatomical structures. Although theinferior shoe 41 is illustrated as convex, and the superior shoe 40 isconcave, note that either shape may be on either end of the medicalimplant, or only shapes of one type or the other only may be a part ofthe medical implant. Shoes of other shapes such as, but not limited to,flat may also be used.

In some embodiments, the superior and inferior shoes, 40, 41 may be madeat least in part from a bioresorbable material. A bioresorbable materialprovides initial support and an initial containment structure forgrafting material that may be placed within the implant. However, overtime, the material dissolves and/or the body removes and replaces thematerial with tissue structures such as bone, thereby providing anespecially open pathway through the implant for tissue growth. Examplesof bioresorbable materials that could be incorporated in the superiorand inferior shoes 40, 41, include but are not limited to allograft,autograft, and xenograft bone materials, polylactide, polyglycolide,tyrosine-derived polycarbonate, polyanhydride, polyorthoester,polyphosphazene, calcium phosphate, hydroxyapatite, bioactive glass, andcombinations thereof.

In other embodiments, the superior and inferior shoes 40, 41 may be atleast in part a bioactive substance proportioned to provide a clinicalbenefit to the recipient of the implant. Bioactive substances includebut are not limited to antibiotics or other substances that affectinfection, bone growth and bone ingrowth promoting substances,substances that treat or attack cancer cells, or any other substancethat makes a therapeutic contribution.

The superior and inferior shoes 40, 41 include shoe connectors 47 forcoupling the shoes 40, 41 to the end caps 30, 30 a. The shoe connectors47 shown are round pins, but in other embodiments could be other shapesand could include other functions. For example, the shoe connectors 47may be square in cross-section or any other geometric shape. The shoeconnectors 47 may be oblong for sliding in slots into which they couldbe engaged, or may have hooked ends to grasp or otherwise capture aportion of the end caps 30, 30 a when coupled. The end caps 30, 30 a mayinclude sliced openings similar to those described in association withthe sliced openings 43 described above. In addition, or in thealternative, the shoe connectors 47 may include relief cuts through someor all of their cross-section to provide a living hinge or spring effectwhen inserted into an appropriately sized opening.

FIG. 12 shows a compliant shoe 45 with shoe splines 46 that support shoeconnectors (not shown) consistent with the shoe connectors 47 describedherein. Between the shoe splines 46 with shoe connectors are shoe hinges49. The shoe hinges 49 may provide living hinges between the shoesplines 46. In other embodiments, the shoe hinges 49 may be mechanicalhinges or may be another material or a differently processed material.The hinged configuration permits the compliant shoe 45 to deform bothangularly and radially in response to loading. Consequently, the implantis less likely to develop local areas of high stress. The shoeconnectors of the compliant shoe 49 may also be more easily snapped intoplace as a result of the flexible characteristics of the device. Loadingamong the shoe connectors may be more easily distributed as a result ofthe properties of the compliant shoe 45.

FIGS. 17 and 18 illustrate an expandable medical implant 100 forsupporting skeletal structures, the expandable medical implant 100having a length along its expandable dimension. In the illustratedembodiment, the expandable medical implant 100 includes a first tubularmember 110 with a connection end 111, an opposite first skeletalinterface end 112, and a central expansion instrument opening 114. Inthe embodiment shown, the central expansion instrument opening 114 issubstantially on the lateral centerline of the first tubular member 110.This is beneficial in some embodiments to provide a central axis alongwhich to expand the expandable medical implant 100. A central liftingpoint avoids eccentricities that may be generated by lifting from pointsbeyond the central axis. In other embodiments, the central expansioninstrument opening 114 may be beyond the central axis, althoughremaining within the periphery of the first tubular member 110.

The expandable medical implant 100 shown also includes a second tubularmember 120 with a connection end 121 configured to engage with theconnection end 111 of the first tubular member 110 by fitting within thesecond tubular member 120. In other embodiments, the first and secondtubular members 110, 120 may partially interdigitate or may have aside-by-side alignment, or other configuration. The second tubularmember 120 has an opposite second skeletal interface end 122. Theembodiment shown includes a bone growth packing aperture 105 throughwhich bone growth material may be packed and through which bone growthmay occur. Additionally, the bone growth packing aperture 105 is an aidin radiographic assessment when the expandable medical implant 100 ismade from a material that is not radiolucent. Lateral openings 106 maybe useful for packing of bone growth material, and provide channelsthrough which bone growth and radiographic assessment may occur.

The term tubular as used herein includes generally cylindrical membersas are illustrated in FIGS. 17-18, but may also include other enclosedor partially enclosed cross-sectional shapes. By way of example andwithout limitation, tubular includes fully or partially, cylindrical,elliptical, rectangular, square, triangular, semi-circular, polygonal,and other cross-sectional shapes of these general types.

As illustrated in FIGS. 17 and 18, the combined first and second tubularmembers, 110,120 are of a greater dimension along the length of theexpandable medical implant 100 than the combined first and secondtubular members 110, 120 are in any dimension perpendicular to theirlength. This aspect ratio may be particularly useful in replacing longstructures that may be best accessed through narrow approaches oropenings.

Embodiments of the invention may also include an expansion instrumentinsertable through the central expansion instrument opening 114. Theinsertion end 140 of such an expansion instrument is illustrated inFIGS. 17 and 18. The expansion instrument insertion end 140 shown has alower segment 140 a and an upper segment 140 b. The lower segment 140 ais expandable against the first tubular member 110, and the uppersegment 140 b is expandable against the second tubular member 120 toexpand the medical implant 100. The lower and upper segments 140 a, 140b shown are semi-circular in cross-section, but may be of any operableshape. Such shapes may be selected to provide improved insertion of theinsertion end 140 into a patient or into an expandable medical implant100, or may be selected for lifting, bearing, bending or shearingstrength, or other characteristics.

As shown in FIGS. 18 and 20, the first tubular member 110 includes thecentral expansion instrument opening 114, which also serves as a reliefcut to facilitate portions of the first tubular member 110 flexing awayfrom the second tubular member 120 to permit translation between thefirst and second tubular members. The flexing may be induced by pushingthe first tubular member 110 away from the second tubular member 120 asdescribed above to expand the implant 100. In other embodiments, thecentral expansion instrument opening 114 may be closed near theconnection end 111 of the first tubular member 110 and not facilitatethe flexing function illustrated.

In other embodiments, a relief cut in the second tubular member 120 anda continuous shape in the first tubular member 110 could cause flexingof the second tubular member 120 rather than the first tubular member110. Similarly, the degree and direction of flexing can be controlled bythe use of different materials, various degrees of relief cutting,different cross-sectional shapes, and the shapes of the teeth orprotrusions employed, among other factors. The force required forvarious degrees of flexing of the members is also proportional to theforce required to expand the implant. Therefore, the force required toexpand the implant may be maintained within a desirable range bycontrolling the factors detailed above.

As best illustrated in FIGS. 19 and 20, the first tubular member 110includes a set of first teeth 115, or more generally, protrusions,wherein each of the rows of teeth are adjacent to one another. Thesecond tubular member 120 includes a set of second teeth 125, or moregenerally, protrusions, wherein the rows of teeth are not adjacent toone another. As shown, every other row of the set of second teeth 125has been removed. However, in other embodiments, every third or fourthor some other member of rows may contain teeth, or the tooth pattern mayrepeat in some non-uniform fashion. If the sets of teeth were threadsinstead, a similar effect could be achieved by widening the pitch of thethreads on one of the tubular members.

The first set of teeth 115 interdigitate with every other one of theteeth of the set of second teeth 125. This or other varied spacings maybe advantageous. As noted above, the force required to expand theimplant is proportional to the number of sets of teeth that are incontact while the tubular members 110, 120 are being translated.However, if teeth on both tubular members are spaced apart at greaterdistances, the number of increments to which the implant may be adjustedis decreased. By maintaining the frequency of the rows of the first setof teeth 115 and increasing frequency of the second set of teeth 125,the force required to expand the implant is reduced, but the number ofdiscrete points of adjustment is not reduced. In some embodiments, theincreased frequency of teeth could be maintained on the second tubularmember 120 while the spacing is increased on the first tubular member110.

In some embodiments, the second tubular member 120 includes aninstrument aperture 130 for receiving at least a portion of theexpansion instrument insertion end 140. Such an instrument aperture mayprovide for stability between the expansion instrument insertion end 140and the expandable medical implant 100 and may provide for additionalspace through which to place the insertion end 140, among otherpurposes.

As illustrated in FIGS. 17 and 18, the width of the insertion end 140 ofthe expansion instrument is less than one half of the width of either ofthe first or second tubular members 11 0, 120. For the purpose ofdescribing the width of the insertion end 140 relative to the tubularmembers 110, 120, the width is a dimension perpendicular to the lengthof the expandable medical implant 100. The width of the insertion end140 and the first or second tubular members 110, 120, should beconsidered in the same plane for the purpose of comparison. In someembodiments, a relatively narrow insertion end 140 is useful tofacilitate visualization of the surgical site while placing theexpandable medical implant 100. A relatively small insertion end 140 mayalso be valuable to reduce the size of the required surgical incision.

In some embodiments, the expandable medical implant may also include abone growth promoting substance. The use of such substances is describedin more detail below.

Some embodiments associated with implant 1, 1 a, 100, and 200 may alsoinclude supplemental fixation devices as part of the expandable medicalimplant for further stabilizing the anatomy. For example, and withoutlimitation, rod and screw fixation systems, anterior or lateral platingsystems, facet stabilization systems, spinal process stabilizationsystems, and any devices that supplement stabilization may be used as apart of the expandable medical implant.

Embodiments of the invention are generally for supporting skeletalstructures, and may include an expandable implant with a first tubularmember and a second tubular member. The expandable implant of someembodiments includes a means for receiving an expansion instrument. Themeans for receiving an expansion instrument may be an aperture orapertures of any type, may be a protrusion or protrusions of any type,may include a friction interface, or any other mechanism designed totransfer force from the expansion instrument to the implant. Theexpansion instrument means is for expanding against the first tubularmember and the second tubular member to expand the implant. Theinstrument means may include device sufficient to separate the first andsecond tubular members.

The expansion instrument means of some embodiments is centrally locatedon the expandable implant such that when the expandable implant isplaced in a person to support the skeletal structures with the expansioninstrument means attached. Ends of the expandable implant that interfacewith the skeletal structure may be viewed from the direction ofinsertion of the expandable implant. In some of these and otherembodiments, lateral extents of the expandable implant are also viewablefrom the direction of insertion of the expandable implant. The termlateral extents is intended to include segments of the expandableimplant such as lateral openings 106 that are located on or near edgesof the expandable implant that are transverse to the insertion directionof the implant.

An embodiment of the invention is a method of placing an expandablevertebral body replacement device such as expandable medical implant 100shown in FIGS. 17 and 18. Embodiments may include making an incisionadjacent to a vertebral body and removing at least a portion of thevertebral body.

As shown in FIG. 17, the expandable medical implant 100 is placed on aninsertion end 140 of an expansion instrument in a contracted position.In the contracted position, the insertion end 140 of the expansioninstrument is configured to pass through a central portion of theexpandable medical implant 100, such as the central expansion instrumentopening 114, without extending onto any surface of the expandablemedical implant 100 that is lateral to an insertion direction. Forexample, the insertion end 140 does not extend onto a lateral extent oreither of the skeletal interface ends 112, 122.

Embodiments of the method may further include inserting the expandablemedical implant 100 at least in part into a volume left open afterremoval of the portion of the vertebral body, expanding the expansioninstrument to secure the expandable medical implant 100, and removingthe expansion instrument through the incision. Some embodiments may alsoinclude placing bone growth promoting substance within the expandablemedical implant 100 prior to expansion of the expandable medical implant100. Further, in some embodiments, bone growth promoting substance mayadditionally or lieu be placed within the expandable medical implant 100after expansion of the expandable medical implant 100.

Additional fixation devices to supplement the fixation of the vertebralbody replacement may be added to the construct in some circumstances.Suitable supplemental fixation devices are described herein and includeothers that provide a clinical benefit.

FIGS. 21-26 illustrate another embodiment of the invention. Anexpandable medical implant 200 with a length along its expandabledimension is shown. The medical implant 200 is for supporting skeletalstructures and has a first tubular member 210 with a connection end 211,including a first set of protrusions 215. The first tubular member 210shown has an opposite skeletal interface end 212. The medical implant200 includes a second tubular member 220 with a connection end 221including a second set of protrusions 225 configured to engage with theconnection end 211 of the first tubular member 210. The second tubularmember 220 includes an opposite end 222 opposite from the connection end221.

FIG. 23 illustrates the expandable implant 200 with a third tubularmember 230. The third tubular member 230 shown has a connection end 231including a third set of protrusions 235 configured to engage with theopposite end 222 of the second tubular member 220. The second tubularmember 220 includes a fourth set of protrusions 227 on the opposite end222. In some embodiments, the first and third tubular member 210, 230,are configured to fit within the second tubular member 220.

As shown in FIGS. 24 and 25B for the third set of protrusion 235, one orboth of the first and third sets of protrusions 215, 235 have a flank240 with a negative flank angle −α′. For the purpose of illustration,only the third set of protrusions 235 is being described in detail, butthe same or directly correlating relationships may be applied to thefirst set of protrusions 215 of FIG. 26.

The term “flank” as used herein is the thread face, excluding any crestor root of the thread profile. The term “flank angle” as used herein isthe angle between the individual flank and a perpendicular 241 to theaxis of the thread measured in the axial plane. As shown, the axis ofthe thread is parallel with the length of the expandable implant 200. Asan example, the sets of protrusions will be described as a threadembodiment, but the protrusions in other embodiments may be notches orratchetings of any operable type.

FIGS. 25A and 25B show a comparison between a typical prior art threadprofile and a thread profile having a negative flank angle. Bothprofiles include the perpendicular 241 to the length of the expandableimplant 200. A load applied as a compression force to an expandableimplant 200 would be transferred to the interface between the threads insome proportion as shown in FIGS. 25A and 25B, the force beingdesignated as P herein. An upper flank 260 and a lower flank 262 areshown for the prior art thread profile with flank angles of α and Θrespectively. Resolved as forces along the flank 260, the force P is aforce normal to the flank F, and a shear force along the flank V. Forreference, arrows designating the results of applying lateral forces tothe third tubular member 230 are provided in FIGS. 25A and 25B. A forceapplied to the left will tend to disengage the threads, and a forceapplied to the right will tend to engage the threads.

As seen with reference to FIG. 25A, the normal force F is directed intothe engaged, opposing flank and the shear force V tends to push a priorart member in the position of the third tubular member 230 along theflank 260. A resultant of the shear force V therefore tends to disengagethe threads. This tendency to disengage may be heightened with devicesthat are designed to expand or contract to flex over other componentparts while expanding. For example, as shown in FIG. 23, the thirdtubular member 230 must flex inwardly to move linearly relative to thesecond tubular member 220 and thus to expand. Analysis along the lowerflank 262 is unnecessary because compressive forces applied to animplant in this configuration tend to separate, not engage the lowerflank 262.

FIG. 25B illustrates an upper flank 240 and a lower flank 242 with flankangles of −α′ and Θ′ respectively. Resolved as forces along the flank240, the force P is a force normal to the flank F′, and a shear forcealong the flank V′. The normal force F′ is directed into the engaged,opposing flank and the shear force V′ tends to push the third tubularmember 230 along the flank 240. A resultant of the shear force V′therefore tends to engage the threads as the flank 240 is positivelyloaded by compressive force on the expandable implant 200. Analysisalong the lower flank 242 is unnecessary because compressive forcesapplied to the expandable implant 200 tend to separate, not engage thelower flank 242.

In a device such as expandable implant 200, maintenance of the implantheight under compressive load requires that the protrusions of thetubular members stay engaged with one another. The negative flank angleprotrusions illustrated in FIG. 25B contribute to the effectiveness andstability of an implant. Although shown with reference to the expandableimplant 200, negative flank angle protrusions may also be applied toexpandable medical implants 1, 1 a, and 100. Zero degree flank anglesare also known, but do not provide the positively engaging force of thenegative flank angle embodiments.

Embodiments of the invention as described in relation to FIGS. 21-26result in implants that, when compressively loaded along the length ofthe implants, generate compressive force between the engaged tubularmember transverse to the length of the implant. As noted, these forcetending to more securely engage the sets of protrusions supporting theimplants.

The term tubular as used herein includes generally cylindrical membersas are illustrated in FIG. 22, but may also include other enclosed orpartially enclosed cross-sectional shapes. By way of example and withoutlimitation, tubular includes fully or partially, cylindrical,elliptical, rectangular, square, triangular, semi-circular, polygonal,and other cross-sectional shapes of these general types.

In alternate embodiments, the opposite end 222 may be configured to be askeletal interface end, rather than connecting to a third tubularmember.

As shown in FIG. 26, the first tubular member 210 includes a relief cut214 to facilitate portions of the first tubular member 210 flexing awayfrom the second tubular member 220 to permit translation between thefirst and second tubular members 210, 220. The flexing may be induced bypulling the first tubular member 210 away from the second tubular member220 to expand the implant 200. In other embodiments, a relief cut in thesecond tubular member 220 and a continuous shape in the first tubularmember 210 could cause flexing of the second tubular member 220 ratherthan the first tubular member 210. Similarly, the degree and directionof flexing can be controlled by the use of different materials, variousdegrees of relief cutting, different cross-sectional shapes, and theshapes of the teeth or protrusions employed, among other factors. Theforce required for various degrees of flexing of the members is alsoproportional to the force required to expand the implant. Therefore, theforce required to expand the implant may be maintained within adesirable range by controlling the factors detailed above. Similarly,the third tubular member 230 may be configured to include one or morerelief cuts 224 (FIG. 23) to facilitate portions of the third tubularmember flexing away from the second tubular member to permit translationbetween the third and second tubular members, and may be the outerrather than the inner member.

As described above with regard to the protrusions of FIGS. 3 and 4, thesets of protrusions of the first, second, and third tubular members 210,220, 230 may include adjacent spacing and non-adjacent spacing invarious embodiments.

The implant FIGS. 23 and 26 includes apertures 205 in the first andthird tubular members 210, 230 through which bone growth material may bepacked and through which bone growth may occur. Additionally, theapertures 205 aid in radiographic assessment when the implant 200 ismade from a material that is not radiolucent. Openings 206 (FIGS. 21 and22) in the second tubular member 220 are also useful for packing of bonegrowth material, and provide channels through which bone growth mayoccur.

Embodiments of the invention include an insertion instrument with alower tip 281 and an upper tip 282, as illustrated in FIGS. 21 and 22.Acceptable devices for driving the lower and upper tips 281, 282 aredisclosed in detail above in association with instruments applied toimplants 1, 1 a, and 100. In addition, some embodiments may includedevices for rotating the second tubular member 220. This rotation may beachieved by inserting a rod or driver into one or more of the openings206 and rotating the second tubular member 220 relative to the firstand/or second tubular members 210, 230. In addition, rotation of thesecond tubular member 220 may be accomplished by devices such as aredisclosed in U.S. patent application 10/663,554, entitled, “ExpansionTool for Adjustable Spinal Implant” filed Sep. 16, 2003, which is herebyincorporated by reference in its entirety, or any other device foreffectively rotating the tubular members 210, 220, and 230.

An embodiment of the invention is an expandable medical implant 200 witha length along its expandable dimension, the medical implant 200 forsupporting skeletal structures. The embodiment includes a first tubularmember 210 with a connection means and a second tubular member 220 witha connections means for coupling with the first tubular member. A meansfor translating the first tubular member 210 relative to the secondtubular member 220 to provide coarse expansion adjustment is providedalong with a means for providing fine length adjustment by turning thesecond tubular member 220 relative to the first tubular member 210. Asillustrate in FIGS. 21-26, the course expansion adjustment means isprovided by separating the lower and upper tips 281, 282 with aninsertion instrument, and the fine adjustment means is accomplished byrotating the second tubular member 220 as disclosed above. Otherconfigurations for the course expansion are contemplated, such as thosedisclosed in relation to implants 1, 1 a, and 100. For embodiments ofimplants 1, 1 a, and 100 to include the fine adjustment capability, theprotrusions of those embodiments could include inclined threads or otherdevices that produce expansion in response to rotation.

An embodiment of the invention is a method of implanting an implant,such as expandable medical implant 200. The expandable medical implant200 has a length along the expandable dimension of the implant. Themethod may include pulling a first tubular member 210 with a first setof protrusions 215, or in some embodiments, threads, away from a secondtubular member 220 with a second set of protrusions 225, or in someembodiments threads, causing the first and second sets of protrusions215, 225 to translate relative to one another along the length of theimplant. Further, in some embodiments, turning the second tubular member220 relative to the first tubular member 210 adjusts the length of theexpandable medical implant 200.

Another method embodiment is also directed to implanting an expandablemedical implant with a length along the expandable dimension of theimplant. An implant such as expandable medical implant 200 may beexpanded by pulling a first tubular member 210 with a first set ofprotrusion 215 away from a third tubular member 230 with a fourth set ofprotrusions 235. In this embodiment, the first set of protrusions 215 isa set of right-hand threads and the fourth set of protrusions 235 is aset of left-hand threads. The expandable medical implant 200 alsoincludes a second tubular member 220 with a second set of protrusions225 and a third set of protrusions 227. In this embodiment, the secondset of protrusions 225 is a set of right-hand threads and the third setof protrusions 227 is a set of left-hand threads.

The act of pulling noted above may cause the first and second sets ofprotrusions, 215, 225, or threads, to translate relative to one anotheralong the length of the implant 200. Similarly, the act of pulling maycause the third and fourth sets of protrusions, 227, 235, or threads, totranslate relative to one another along the length of the implant 200.In some embodiments, turning the second tubular member 220 relative tothe first and third tubular members 210, 230 will adjust the expandedlength of the expandable medical implant 200. Turning in a firstdirection will cause shortening of the expandable medical implant 200,and turning in an essentially opposite direction will cause lengtheningof the expandable medical implant 200. For example, turning the secondtubular member 220 clockwise shortens the expandable medical implant200, and turning the second tubular member 220 counter-clockwiselengthens the expandable medical implant 200.

Various method embodiments of the invention are described herein withreference to particular implants 1, 1 a, 100, and 200. However, in somecircumstances, each disclosed method embodiment may be applicable toeach of the implants 1, 1 a, 100, and 200, or to some other implantoperable as disclosed with regard to the various method embodiments.

In some circumstances, it is advantageous to pack all or a portion ofthe interior and/or periphery of the implants 1, 1 a, 100, 200 with asuitable osteogenic material or therapeutic composition. Osteogenicmaterials include, without limitation, autograft, allograft, xenograft,demineralized bone, synthetic and natural bone graft substitutes, suchas bioceramics and polymers, and osteoinductive factors. A separatecarrier to hold materials within the device may also be used. Thesecarriers may -include collagen-based carriers, bioceramic materials,such as BIOGLASS®, hydroxyapatite and calcium phosphate compositions.The carrier material may be provided in the form of a sponge, a block,folded sheet, putty, paste, graft material or other suitable form. Theosteogenic compositions may include an effective amount of a bonemorphogenetic protein (BMP), transforming growth factor β1, insulin-likegrowth factor, platelet-derived growth factor, fibroblast growth factor,LIM mineralization protein (LMP), and combinations thereof or othertherapeutic or infection resistant agents, separately or held within asuitable carrier material. A technique of an embodiment of the inventionis to first pack an unexpanded implant, as shown in FIGS. 14A and 14B,with material and then place one or both end members if desired. Uponexpanding the device to an expanded state such as is shown in FIG. 2,material may additionally be placed through the medial aperture 5 and/oropenings 6. Placement may be accomplished directly or with the aid of aninjection or transfer device of any effective type. Such a technique maybe practiced for implants 1, 1 a, 100, and 200 as well.

Embodiments of the implant in whole or in part may be constructed ofbiocompatible materials of various types. Examples of implant materialsinclude, but are not limited to, non-reinforced polymers,carbon-reinforced polymer composites, PEEK and PEEK composites,shape-memory alloys, titanium, titanium alloys, cobalt chrome alloys,stainless steel, ceramics and combinations thereof. If the trialinstrument or implant is made from radiolucent material, radiographicmarkers can be located on the trial instrument or implant to provide theability to monitor and determine radiographically or fluoroscopicallythe location of the body in the spinal disc space. In some embodiments,the implant or individual components of the implant are constructed ofsolid sections of bone or other tissues. In other embodiments, theimplant is constructed of planks of bone that are assembled into a finalconfiguration. The implant may be constructed of planks of bone that areassembled along horizontal or vertical planes through one or morelongitudinal axes of the implant. Tissue materials include, but are notlimited to, synthetic or natural autograft, allograft or xenograft, andmay be resorbable or non-resorbable in nature. Examples of other tissuematerials include, but are not limited to, hard tissues, connectivetissues, demineralized bone matrix and combinations thereof. Examples ofresorbable materials that may be used include, but are not limited to,polylactide, polyglycolide, tyrosine-derived polycarbonate,polyanhydride, polyorthoester, polyphosphazene, calcium phosphate,hydroxyapatite, bioactive glass, and combinations thereof. Implant maybe solid, porous, spongy, perforated, drilled, and/or open.

FIG. 1 illustrates four vertebrae, V₁-V₄, of a typical lumbar spine andthree spinal discs, D₁-D₃. While embodiments of the invention may beapplied to the lumbar spinal region, embodiments may also be applied tothe cervical or thoracic spine or between other skeletal structures.

While embodiments of the invention have been illustrated and describedin detail in the disclosure, the disclosure is to be considered asillustrative and not restrictive in character. All changes andmodifications that come within the spirit of the invention are to beconsidered within the scope of the disclosure.

1. An expandable medical implant for supporting skeletal structurescomprising: a first tubular member with a connection end and an oppositeskeletal interface end; a second tubular member with a connection endconfigured to engage with the connection end of the first tubularmember, the second tubular member having an opposite skeletal interfaceend; and a key pin fixed to the first tubular member and positioned in aslot in the second tubular member so that the key pin guides translationbetween the first tubular member and the second tubular member.
 2. Theexpandable medical implant of claim 1 wherein the first tubular memberfits within the second tubular member.
 3. The expandable medical implantof claim 1 wherein the first tubular member includes a relief cut tofacilitate portions of the first tubular member flexing away from thesecond tubular member to permit translation between the first and secondtubular members.
 4. The expandable medical implant of claim 1 whereinthe first tubular member includes a set of adjacent protrusions.
 5. Theexpandable medical implant of claim 4 wherein the second tubular memberincludes a set of protrusions that are not all adjacent and thatinterdigitate with one or more of the adjacent protrusions.
 6. Theexpandable medical implant of claim 1 wherein the first and secondtubular members are generally cylindrical.
 7. The expandable medicalimplant of claim 1 wherein the key pin contributes to torsionalstability between the first tubular member and the second tubularmember.
 8. The expandable medical implant of claim 1 wherein the key pinis a stop for movement of the first tubular member relative to thesecond tubular member.
 9. The expandable medical implant of claim 1further comprising an insertion instrument for expanding the implant,wherein the implant progressively locks as expanded by motion of atleast a portion of the insertion instrument in a first direction, andthe locked implant releases by motion of the portion of the insertioninstrument in a generally opposite direction.
 10. The expandable medicalimplant of claim 9 wherein the locked implant is released by applying aforce to the key pin.
 11. An expandable medical implant for supportingskeletal structures comprising: a first tubular member with a connectionend and an opposite skeletal interface end; a second tubular member witha connection end configured to engage with the connection end of thefirst tubular member, the second tubular member having an oppositeskeletal interface end; wherein the second tubular member intermittentlylocks relative to the first tubular member as the implant is expanded;and an insertion instrument for translating the first tubular memberrelative to the second tubular member comprising: a first tip forattaching to the skeletal interface end of the first tubular member, asecond tip for attaching to the skeletal interface end of the secondtubular member, and a spreader mechanism for translating the first tipaway from the second tip; wherein moving the first tip toward the secondtip results in the first tubular member being released relative to thesecond tubular member to permit the expandable medical implant to bereduced in length.
 12. The expandable medical implant of claim 11wherein the second tip includes a capture mechanism for engaging aportion of the implant that releases locking between the first andsecond tubular members.
 13. The expandable medical implant of claim 12wherein the capture mechanism connects the insertion instrument to thefirst and second tubular members to facilitate positioning or removal ofthe first and second tubular members.
 14. The expandable medical implantof claim 11 wherein the first tip includes a capture mechanism forengaging a portion of the implant that releases locking between thefirst and second tubular members.
 15. The expandable medical implant ofclaim 14 wherein the capture mechanism connects the insertion instrumentto the first and second tubular members to facilitate positioning orremoval of the first and second tubular members.
 16. The expandablemedical implant of claim 11 further comprising a set of two or morevariously sized first interchangeable tips that may be placed one at atime on the insertion instrument in the position of the first tip toaccommodate first tubular members of different, matching sizes.
 17. Theexpandable medical implant of claim 11 further comprising a set of twoor more variously sized second interchangeable tips that may be placedone at a time on the insertion instrument in the position of the secondtip to accommodate second tubular members of different, matching sizes.18. An end member for a medical implant having a length, the end memberconfigured to interface with a skeletal structure at the end of itslength, comprising: an end cap with a thickness that provides connectionto the medical implant and connection to the skeletal structure; and ashoe for attachment to the end cap, the shoe spanning at least a portionof an opening through the end cap, and providing at least in part aninterface with the skeletal structure.
 19. The end member of claim 18wherein the medical implant is a corpectomy device.
 20. The end memberof claim 18 wherein the end cap varies in thickness such that placementof the end member on the medical implant creates an interface with theimplant that is not parallel to the length of the implant.
 21. The endmember of claim 20 wherein the end member and medical implant match thenatural angles of a spinal curvature.
 22. The end member of claim 21wherein the angles of spinal curvature are lordotic angles.
 23. The endmember of claim 18 wherein the end cap includes surface irregularitiesto aid interface with the skeletal structure.
 24. The end member ofclaim 23 wherein the surface irregularities are sharp spikes thatpenetrate the skeletal structure.
 25. The end member of claim 18 whereinthe end cap includes cap connectors for coupling the end cap to themedical implant.
 26. The end member of claim 25 wherein the capconnectors are pins.
 27. The end member of claim 25 wherein the medicalimplant includes an opening for receiving a cap connector, the openinghaving a cut from the opening through at least of portion of thesurrounding material to provide a living hinge to securely receive thecap connector in the opening.
 28. The end member of claim 18 wherein theshoe is convexly shaped relative to the end member.
 29. The end memberof claim 18 wherein the shoe is concavely shaped relative to the endmember.
 30. The end member of claim 18 wherein the shoe is at least inpart a bioresorbable material.
 31. The end member of claim 18 whereinthe shoe is at least in part a bioactive substance.
 32. The end memberof claim 18 wherein the shoe includes shoe connectors for coupling theshoe to the medical implant.
 33. The end member of claim 18 wherein theshoe includes hinges between the shoe connectors.
 34. A method ofplacing a medical implant between skeletal structures with an insertioninstrument comprising the acts of: accessing a surgical site; expandingthe medical implant to fit in a space between skeletal structures bymoving at least a portion of the insertion instrument in a firstdirection, wherein the medical implant progressively locks as expanded;and if the locked implant needs to be released from the locked position,releasing the locked implant by moving of the portion of the insertioninstrument in a generally opposite direction.
 35. The method of claim 34wherein the act of expanding the medical implant by moving at least aportion of the insertion instrument in a first direction includesrotating the portion of the insertion instrument in a clockwisedirection.
 36. The method of claim 34 wherein the act of releasing thelocked implant by moving of the portion of the insertion instrument in agenerally opposite direction includes rotating the portion of theinsertion instrument in a counter-clockwise direction.
 37. An expandabledevice for supporting skeletal structures comprising: an implant meansfor expanding into a space between skeletal structures in aprogressively locked state; an instrument means for expanding theimplant into the space by movement of at least a portion of theinstrument in a first direction, wherein movement of the at least aportion of the instrument in a generally opposite direction releases thelocked state of the implant.